The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular...
Transcript of The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular...
![Page 1: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/1.jpg)
CO-LaN Meeting in Leipzig-Schkopau
Verfahrenstechnik I Verfahrenstechnik III
The SolidSim Project
Development of a Flowsheeting Tool
for Solids Processes
![Page 2: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/2.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
1
Outline
• The SolidSim Project
– Project introduction
– Design concept of Simulation Software
• CAPE-OPEN and SolidSim
• Demonstration of SolidSim
![Page 3: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/3.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
2
Motivation
• Flowsheet simulator for solids processes allows
– development of flowsheets for complex processes
– design studies for process alternatives
– sensitivity analysis for process parameters
– fast and easy optimization of processes involving solids
• Establish a model library for solids processing
equipment and unit operations
• Support education of chemical engineering students
![Page 4: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/4.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
3
Comparision - Simulation of …
• Liquid/gas process– concentrated variables
(temp., pressure, mass fraction)
– complete characterization by few
parameters(temp., composition, pressure)
– models cover mass transfer and
reactions
– equipment geometry plays minor
role in modeling (just influence on residence time)
– throughput influences only
residence time
• Solids processing– additional distributed parameters
(particle size distr., density distr.)
– characterization requires more
parameters(shape factor, size distribution,
porosity, breaking behaviour, etc.)
– partially dependant secondary
attributes(particle size dep. composition (ore)
or moisture content, surface area
dependant contamination)
– model has to account for very
complex physical effects(e.g. impact mill, dryer, fluidized bed)
• most models only valid for certain
operating conditions
Solids require a very complex
information structure
![Page 5: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/5.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
4
Commercial Simulators I
• Commercial simulators can be divided into two
groups:
– equation based systems
• system is modeled as one large equation system and solved
parallel for all variables
– DIVA, gProms, SpeedUp, Aspen Custom Modeler
– sequential modular aproach
• process is divided into connected logical blocks as in a flowsheet
• blocks are then solved individually
• recycles solved by iterative solution of the system
– ASPEN Plus, Hyprotech HySim
![Page 6: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/6.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
5
Commercial Simulators II
• Problems of available sequential modular systems:
– Model quality/quantity
• generally only a few models available for solids processing
• models usually have low detail level (short-cut models, empirical
correlations)
– Stream structures supported
• most simulators originate from liquid/gas process industry
• concentrated parameters such as temperature, pressure, etc. are
supported, plus in some cases simple support for distributed
parameters such as PSD, but no secondary dependend attributes
![Page 7: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/7.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
6
Commercial Simulators III
• Characteristics of equation based simulators
– High flexibility due to equation based design:
• almost any model can be implemented as long as equations are
given and solver supports type of equations
• custom parameters can be introduced with ease
– Input of problem requires knowledge of “programming
language” → syntax, conventions, etc.
– Every single model has to be implemented by including
the equations → high effort for a simple problem
– Equation sets get very large, flowsheeting based
simulator is closer to engineers view on process
![Page 8: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/8.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
7
Requirements for a Simulator
• support of flexible information structure for streams (distributed and concentrated parameters, standard and custom parameters)
• allow combination of models for individual equipment and process steps to be combined to complex process flowsheet, no limitation to special processes
• presence of fluids and solid/liquid interactions have to be considered
• ergonomic easy-to-use Graphical User Interface (GUI) to allow engineer to build process following his view (flowsheet focussed)
• extendable model database including model backgrounds (mathematical and engineering), model boundaries (valid operating conditions), etc.
• standardized interfaces (e.g. CAPE-OPEN) to other “liquid/gas simulators”
![Page 9: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/9.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
8
1995-1998 Project „Modellierung komplexer Feststoffprozesse“ (‚Modelling
of complex solids processes‘) funded by VW-Stiftung
→ Development of program and information structures,
programming of simulation system SolidSim,
simulation of exemplary industrial processes,
no graphical user interface
1999-2002 Attempts to get funding of follow-up projects
• Proposal in 5th EU framework
• Proposal for a AiF project (TUHH only)
→ request to submit a proposal for a cooperation project
→ search for project partners
2003 Begin of funding of cooperation project „Fließschema-Simulation
von Feststoffprozessen“ (‚Flow sheet simulation of solids
processes‘) by AiF
• Cooperation of 11 universities
• Advisory committee of industrial partners
Simulation of Solids Processes at TUHH
![Page 10: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/10.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
9
Strategy for Development
• solids processing discipline involves huge number of
different process steps and equipment types
• work load can not be handled by one partner
• solids processing discipline is divided into packages and
distributed for responsible processing to “most
knowledgeable experts” amongst German Universities
• industrial partners of SolidSim project will stand as godfather
for each single package (both, from industrial users & vendors of related equipment)
• throughout project lifetime there will be several field tests of
intermediate results in industry (by industrial partners) to
ensure applicability of system and quality of models
![Page 11: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/11.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
10
SolidSim Developers
COSE GUI, Interfaces G. Gruhn, J. Werther, Hamburg
Size Reduction Mills W. Peukert, Erlangen
Solid-Liquid Separation Filtration
Centrifuge / Decanter
Hydrocyclone
Thickener
S. Ripperger, Dresden
W. Stahl, Karlsruhe
J. Werther, Hamburg
J. Werther, Hamburg
Gas-Solid Separation Gas cyclone
Filter
Scrubber
Electrostatic Precipitator
J. Werther, Hamburg
E. Schmidt, Wuppertal
E. Schmidt, Wuppertal
E. Schmidt, Wuppertal
Classification Sifter
Sieve
Stream classifier
E. Schmidt, Wuppertal
J. Werther, Hamburg
J. Werther, Hamburg
Agglomeration
Granulation
Fluidized Bed Granulator
Pressure Agglomerator
L. Mörl, Magdeburg
Drying Convective Dryer E. Tsotsas, Magdeburg
Crystallisation
Dissolving
Crystallizer M. Kind, Karlsruhe
Conveying
Dossage
dilute phase conveying
dense phase conveying
Dosage
K.-E. Wirth, Erlangen
Spray Spray nozzles P. Walzel, Dortmund
Fluidization Fluidization J. Werther, Hamburg
![Page 12: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/12.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
11
SolidSim Timetable
03
12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3
Selection of test process
Simulation tests with Short-Cut-
Version
Development of detailed models
Model documentation / help
system
Sensitivity analysis
Implementation of methods for
process optimization
Simulation tests using detailed
models
beta testing by selected users
20052004
2. Project Meeting
(09.12.2003)3. Project Meeting
(27.04.2004)
Committal of
detailed models
(30.09.2004)
4. Project Meeting
Committal of
help system
(20.12.2004)
![Page 13: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/13.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
12
SolidSim Simulation Environment
Material Stream Object
Design Concept of SolidSim
• Software consists of
– simulation environment
– material stream objects
– unit models
Unit Model
+ base unit →framework
![Page 14: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/14.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
13SolidSim Simulation Environment
Material Stream Object
Functions of the SolidSim Framework
• Providing access to model library– allows for easy development of new models by providing standard programming
interfaces and a base module for easy implementation of unit specific models
– dynamic integration of the unit models into the simulation environment
– allows to connect individual models to set up a complex flowsheet
• Graphical user interface– visualization of the flowsheet
– dialog based user interactions
• Simulation engine– coordination of flowsheet calculation
– control of data exchange between unit models and material stream objects during calculation
• Help system– for simple access to documentation of simulation environment and unit models
Unit Model
![Page 15: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/15.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
14SolidSim Simulation Environment
Material Stream Object
Functions of the SolidSim Framework
• Stream Objects
Transports stream information from one unit model to the next
→ Information Stream: Information about process parameter
→ Energy Stream: Information about transferred energy
→ Material Stream: Information about material stream of physical properties
• Providing access to all stream data necessary for the simulation– Handling of concentrated variables (temperature, pressure) and distributed properties
as well (particle size distribution, etc.)
– Access to physical property package through standardized interfaces
• Conversion and calculation of derived properties– Example: calculation of thermal velocity distribution out of given particle size
distribution and density distribution
Unit Model
![Page 16: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/16.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
15
SolidSim Simulation Environment
Material Stream Object
Model Library - Guidelines
• models will be constantly maintained and supported by experts from University
• models have to be accurately evaluated and tested in industrial applications
• including godfathers from industry ensures practical applicability and relevance
• models have to have good documentation
• models can be replaced by new improved models easily
• new models can be developed and implemented without access to source code of framework
Unit Model
![Page 17: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/17.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
16• SolidSim utilizes CAPE-OPEN interfaces wherever
possible because of the following benefits:– Software development
• shorter development time using existing interface specification
• Interfaces are validated
– Interoperability• CO compatible units can be used in all COSE‘s
• One COSE might be used as an unit within an other COSE in a flow sheet
• Existing solver, physical property packages, databases can easily be used
• With the existing CAPE-OPEN interfaces one cannot handle distributed solids parameters– TUHH became an associated member of the CO-LaN in February
– proposal for the extension of the standard was submitted by TUHH at the end of 2003
CAPE-OPEN-Standard
![Page 18: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/18.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
17
Folie 3
SolidSim – Structure of Simulation
System
Interface for unit
initialization and
calculation control
Framework: GUI,
model library,
simulation engine
Provides unit
model with
physical
properties and
stream data
Interface for physical
properties and stream
data
Unit specific
simulation
external Physical
Properties System
external Unit Model
![Page 19: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/19.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
18
Inlet
streams
Unit model
Specific model
Base unit
Calculate
Done
Stream data / physical
properties
Simulation Environment
Outlet
streams
ICapeUnit
ICapeThermo+
• Base unit provides functionality
- to simplify communications with stream objects
- to do standard operations (copying inlet to outlet streams)
- ensures CAPE-OPEN 0.9.3, 1.0 and 1.1 compatibility
• Specific unit model
- inherits functionality of the base unit
- implements unit specific simulation only
→ Unit model developers can concentrate on process simulation
SolidSim – Unit Model
![Page 20: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/20.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
19
• global definition of all
compounds used for simulation
• theoretical unlimited number of
phases
– Phase definition
• Phase fraction and
composition
• Definition of discrete
and distributed
properties for each
phase
• MO can utilize any CAPE-OPEN
compatible physical property
package to request physical
property or flash calculations
• Access to global constants
Material Stream Object
Transports stream information from one unit model to the next and provides accessto physical properties
![Page 21: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/21.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
20
Material Stream Object / Distributed Properties
• Distributed properties are stored in a n-dimensional matrix where n is the number of
defined properties
• Each element of the matrix is defining the fraction of the particles that can be
characterized by a certain combination of properties classes
• The class definition of the distributed properties is stored separately
particle size density form factor
particle size
de
nsity
![Page 22: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/22.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
21
Material Stream Object / Changing
Distributed Properties
• redistribution of mass fractions into existing classes by applying a movement
matrix
• entry in movement matrix represents fraction of the material that is moved from
the old into the new class
• movement matrix is calculated by the unit model and applies only to the properties
the unit requested
• after calculation the unit returns the movement matrix to the framework
• the framework is calculating the new property matrix based on movement matrix
nnn
n
n
kkn
...
kk
kk
n...
,1,
,21,2
,11,1
......
............
......2
......1
21to
from
Example: movement matrix
applied to one distributed
property
![Page 23: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/23.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
22
Extending the Standard
• Extending the existing list of thermo properties
• The functions GetSinglePhaseProp, GetTwoPhaseProp, GetOverallProp will return an interface pointer if a distributed property is requested.
• Adding the following Interface
– ICapeDistributedProperty
• GetDistribution
• GetDistributionState
• GetDistributionClassDefinition
• ApplyMovementMatrix
This interface provides functionality to access distributed properties and to change the fractions by applying a movement matrix.
New classes cannot be added.
The initialization of the distributed properties has to be done through a proprietary interface
orequivalent Set-Functions have to be added to the standard.
![Page 24: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/24.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
23
CapeOpen 1.1 Thermo Interfaces
ICAPEDistributedProperty
+GetDistribution()
+GetDistributionList()
+GetDistributionState()
+GetDistributionClassDefinition()
+ApplyMovementMatrix()
+SetDistribution()
+SetDistributionState()
+SetDistributionClassDefinition()
![Page 25: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/25.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
24
RWK flow sheet
250mm
63mm
100mm
45mm
split size
300 / 225 mmFeed:
Q = 100 t/h
dp50 = 330mm
dp95 = 880mm
![Page 26: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/26.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
25
• Problem:fine solids are highly contaminated
• Solution:Separation of the fines in a hydrocyclone cascade
SolidSim
Application:
sewage sludge Sample:
average contamination
71 ppm
lead, ppm
particle size, mm
mass fraction,
cumulative
![Page 27: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/27.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
26
Hydrocyclone – Separation Efficiency
![Page 28: The SolidSim Project - CO-LaN– DIVA, gProms, SpeedUp, Aspen Custom Modeler –sequential modular aproach • process is divided into connected logical blocks as in a flowsheet •](https://reader030.fdocuments.in/reader030/viewer/2022040906/5e7c1678322931028b25abc5/html5/thumbnails/28.jpg)
CO-LaN Meeting 13.02.2004
Verfahrenstechnik I Verfahrenstechnik III
27
Thank you for your attention!!
Matthias Pogodda
Denickestr. 15
21073 Hamburg
+49 40 42878-3282